Service Update

SU2103 Shaw J1939 DEF Sensor Troubleshooting Guide

Models Affected: Vision (BBCV), All American, and TX4 (T3FE, T3RE), with EPA/CARB certified on highway Cummins® Diesel Engine Features Built After 01/18/2016
Subject: The intent of Service Update SU2103 is to announce a “New Shaw Development® Technical Bulletin”. The Technical Bulletin is intended to guide Shaw Development® customers in
troubleshooting fault codes related to the DEF tank assembly on Cummins® engine equipment. This document is intended to be a “living document”, and the details and processes within
can/will change as system designs evolve, or other new information comes to light. Access to this Shaw Development® Technical Bulletin is also available on the Blue Bird Vantage website noted
below.
WARNING:
Always follow all Federal, State, Local and Shop safety standards and use proper safety equipment, and thoroughly read and understand all instructions before performing these procedures.
Park bus on level surface, apply parking brake, turn off ignition key, and chock wheels.
Information:
Shaw Development® manufactures and supplies the diesel exhaust fluid (DEF) tank assemblies installed on Blue Bird buses powered with Cummins® Diesel engines.
Technical Bulletin Document No: 0000297252 (attached) is intended to supplement existing Shaw Development® service documents that are currently available.
As noted this document is intended to be a “living document”, therefore to ensure you always have the latest revision it is highly recommended that the document be downloaded from the Blue Bird
Vantage website by clicking here. https://vantage.blue-bird.com/Portal/supplier-documentation-P-and-S.aspx

Shaw Development® Bulletin Tools And Equipment:
Item
Number
Part Number
Description
1
BB# 10058812
Shaw Scan Gauge diagnostic tool
2
Cummins®
Cummins ECM diagnostics application (Insite)
3
Cummins®/Industry Suppliers RP1210 Communication Adapter (Inline/DPA5/Nexiq)
4
Cummins®
Refractometer calibrated for measuring DEF
5
Industry Suppliers
Digital Multimeter
6
Industry Suppliers
Temperature measurement device
7
Industry Suppliers
Infrared temperature measurement device
8
Cummins® QuickServe®
Cummins® field support portal for service information

1

Quantity
1
1
1
1
1
1
1
1

25190 Bernwood Dr
Bonita Springs, FL 34135
239-405-6100
www.shawdev.com

DIGITAL SENSOR FIELD TROUBLESHOOTING GUIDE
DOCUMENT NO: 0000297252
Version: B

Status:Approved

VERSION HISTORY
Version
A
B

Implemented
By

Revision
Date

Christian Braun 1/31/2021
Christian Braun 2/16/2021

Reason
Initial draft
Removed watermark

TABLE OF CONTENTS
1 INTRODUCTION ............................................................................................................................................ 3
1.1
Purpose of Technical Bulletin ..................................................................................................... 3
1.2
Applicable Part Numbers, Assemblies and/or Applications....................................................... 3
1.3
Required Tools and Equipment .................................................................................................. 3
1.4
Definitions/Acronyms ................................................................................................................... 4
2 HEADER/SENSOR GENERATION IDENTIFICATION................................................................................ 5
2.1
Gen4 Header With Analog Sensor ............................................................................................. 5
2.2
Gen4 Header with Digital Sensor ............................................................................................... 7
2.3
Gen5 Header with Analog Sensor .............................................................................................. 9
2.4
Gen5 Header with Digital Sensor ............................................................................................. 11
2.5
Gen6 and Gen7 Header (MSU Sensor) ................................................................................... 13
3 FAULT CODES ............................................................................................................................................ 15
3.1
Discussion.................................................................................................................................. 15
3.2
DEF System Fault Code Details ............................................................................................... 15
4 PROCEDURES............................................................................................................................................. 18
4.1
Read ECM Fault Codes ............................................................................................................ 18
4.2
Obtaining a Cummins Insite Job Image.................................................................................... 18
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC.
© 2017 Shaw Development, LLC. All rights reserved.

Technical Bulletin: 0000297252
Version: B
Page 2 of 25
4.3

Abnormal Update Rate Fault Codes (3868, 4572, 4677) ........................................................ 19
4.3.1 Discussion............................................................................................................................ 19
4.3.2 Troubleshooting Procedure................................................................................................. 19
4.4
Level Sensor Abnormal Rate of Change (4769) ...................................................................... 20
4.4.1 Discussion............................................................................................................................ 20
4.4.2 Troubleshooting Procedure................................................................................................. 20
4.5
Quality Sensor Abnormal Rate of Change (4277) ................................................................... 21
4.5.1 Discussion............................................................................................................................ 21
4.5.2 Troubleshooting Procedure................................................................................................. 21
4.6
Sensor Element Open/Short Circuit (FMI3 and FMI4 in Table 3) ........................................... 24
4.6.1 Discussion............................................................................................................................ 24
4.6.2 Troubleshooting Procedure................................................................................................. 24
4.7
DEF Tank Temperature Evaluation .......................................................................................... 24
4.7.1 Discussion............................................................................................................................ 24
4.7.2 Procedure ............................................................................................................................ 24
4.8
DEF Tank Coolant Loop Evaluation ......................................................................................... 25
4.8.1 Discussion............................................................................................................................ 25
4.8.2 Procedure ............................................................................................................................ 25

NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC.
© 2017 Shaw Development, LLC. All rights reserved.

Technical Bulletin: 0000297252
Version: B
Page 3 of 25

1

INTRODUCTION

1.1 Purpose of Technical Bulletin
The Technical Bulletin is intended to guide Shaw Development customers in troubleshooting fault
codes related to the DEF tank assembly on Cummins engine equipment.
This document is intended to be a “living document”, and the details and processes within can/will
change as system designs evolve, or other new information comes to light.

1.2 Applicable Part Numbers, Assemblies and/or Applications
Table 1
Source

Document No.

Title/Description

1

Shaw

DMCXX-XXXXXXXX

Gen4 headers with digital sensor

2

Shaw

DRCXXX-XXXXXXXX

Gen4 tank assemblies with digital sensor

3

Shaw

DM5XX-XXXXXXXX

Gen5 headers

4

Shaw

DR5XXX-XXXXXXXX

Gen5 tank assemblies

5

Shaw

DM6XX-XXXXXXXX

Gen6 headers

6

Shaw

DR6XX-XXXXXXXXXX Gen6 tank assemblies

7

Shaw

DM7XX-XXXXXXXX

8

Shaw

DR7XX-XXXXXXXXXX Gen7 tank assemblies

Gen7 headers

1.3 Required Tools and Equipment
Table 2
Source

Equipment Name/PN

Description

1

Shaw

960-0232-01-K

Shaw Scan Gauge diagnostic tool

2

Cummins

Insight

Cummins ECM diagnostics application

3

Cummins

Inline 6/7

Cummins J1939 service tool

4

Cummins

DEF Refractometer

Refractometer calibrated for measuring DEF

5

Cummins

Quickserve Portal

Cummins field support portal

6

Digital Multimeter

7

Thermocouple

Temperature measurement device

8

IR Thermometer

Infrared temperature measurement device

NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC.
© 2017 Shaw Development, LLC. All rights reserved.

Technical Bulletin: 0000297252
Version: B
Page 4 of 25

1.4 Definitions/Acronyms
•
•
•
•
•
•
•
•
•

CCV
Coolant Control Valve
DEF
Diesel Exhaust Fluid
ECM
Engine Control Module
FMI
Failure Mode Indicator
J1939
SAE CAN Communication Protocol
MFHU
Multi-Function Head Unit
MSU
Multi-parametric Sensor Unit
SAE
Society of Automotive Engineers
SPN
Suspect Parameter Number

NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC.
© 2017 Shaw Development, LLC. All rights reserved.

Technical Bulletin: 0000297252
Version: B
Page 5 of 25

2

HEADER/SENSOR GENERATION IDENTIFICATION

Depending on the equipment vintage, there are multiple generations of DEF headers/sensors which
could be encountered in the field. In order to assist personnel in troubleshooting, distinguishing
features which can be used to identify which generation of Shaw products is being worked on are
detailed below. Gen4 and Gen5 headers were produced with both the digital sensor, as well as analog
sensors. Gen6 and Gen7 headers are only available with MSU sensors.

2.1 Gen4 Header With Analog Sensor
The Gen4 header with analog sensor is shown below. The contents of this document are typically not
relevant to this product. From the exterior of the tank, this generation can be distinguished by a round,
black sensor mounted into the DEF header, offset from center. Sensor part and serial numbers are
present on the body of the sensor. Internally to the tank, a white plastic “focus tube” can be observed.

Sensor

Focus Tube

Figure 1: Gen4 Header with Analog Sensor

NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC.
© 2017 Shaw Development, LLC. All rights reserved.

Technical Bulletin: 0000297252
Version: B
Page 6 of 25

Figure 2: Gen4 Header with Analog Sensor Exterior Closeup

NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC.
© 2017 Shaw Development, LLC. All rights reserved.

Technical Bulletin: 0000297252
Version: B
Page 7 of 25

2.2 Gen4 Header with Digital Sensor
The Gen4 header with digital sensor is shown below. From the exterior of the tank, this generation can
be distinguished by a laser etched bent stainless steel plate offset from center in the header, which is
marked with a 11-digit serial number, a part number of the format ‘XXXX-XX’ or ‘XXXX-XXXX’, and a
revision code of the format ‘XX_X XXXXXX’. Additionally, the wire harness on this generation comes
out of the sensor at a 90° angle. Gen4 digital sensors went through two iterations of design. Internally
to the tank, the earlier iteration did not include the aeration shroud (see Figure 3), while the later
generation did (see Figure 4).